Apparatus for forming a carton



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APPARATUS FOR FORMING A CARTON Filed June 22, 1953 ll Sheets-Sheet ll United States Patent M signments, to Marathon C orporaliomkothschild, Wis., a corporation of Wisconsin Application June 22, 1953, Serial No. 363,236 7 2 Claims. (Cl. 93'--s1 This invention relates to a new and useful method of and apparatus for forming a carton, particularly a dispensing carton of the type shown and described in United States Patent No. 2,624,521, issued January 6, 1953, to Frank L. Broeren. a A

The formation of such cartons, to contain a roll of sheet material, such as waxed paper, which is manufactured, sold and used in tremendous quantities, must of necessity from that fact be completed in a very high speed operation if commercial success in the sale of the carton-contained product is to be achieved. My invention provides a method and means particularly adapted to such high-speed formationof the carton.

In common practice, such cartons are initiallyformed as cut and scored blanks, which may be shipped to the point where they are to be set up and filled with the contained product. This method of operation provides great saving in transportation and storage costsgas compared with the result if the cartons were .to be initially set up and then shipped to,.the point at whichthey. were to be filled with the productfSin ce the places of setting up of the cartons may be fairly numerous, it is highly desirable that the means devised for forming the finished carton be of the least possible cost. Myinvention provides means "involving a cost well within the realm of successful commercial practice. i

The numerous objects and advantages of my invention will be readily evident from the following description and drawings, in which:

Figure 1 is a perspective view of the carton blank from which the carton is formed by my invention,

Figure 2 is a perspective view, partially cut away, showing the finished carton set up by my invention, and containing the roll of sheet material to be dispensed therefrom in suitable lengths,

Figure 3 is a front perspective view of my machine,

Figure 4 is a detailed perspective view, partially cut away, showing the left-handv portion of the machine illustrated in Figure 3. i

Figrue 5 is a detailed perspective view, partially cut away, showing the right-hand portion of the machine illustrated in Figure 3.

Figure 6 is a rear perspective view, partially cut away, showing details of the machine illustratedin Figure 3,

Figure 7 is a cross-sectional view, partially cut away, taken along the line 7- -7 of Figure 6,

Figure 8 is a front perspective operating view, partially cut away, of a portion of the machine illustrated in Figure 3, showing the initial stage of formation of the carton from the carton blank illustrated in Figure 1,

Figure 9 is a front perspective view similar to Figure 8, showing a further stage in the formation of the carton as illustrated in Figure 15,- the carton blank being partially cut away, g p

Figure 10 is a front perspective view similar to Figure 9, showing a still further stage in the formation-of the' carton as illustrated in Figure 16, the carton blank being partially cut away,

2 ,738,715 Patented Mar. 20, 1956 Figure 11 is a front perspective view of a portion of that part of my machine shown in Figure 9, showing a still further stage in the formation of the carton as illustrated in Figure 17, the carton blank being partially cut away, A

Figure 12 is afront perspective view, partially cut away, of the left-hand portion of my machine, showing a still further stage in the folding of the end flaps of the carton, Y

Figure 13 is a'front perspective view, similar to Figure 12, showing a still further stage in folding the end flaps of the carton,

Figure 14 is a perspective view, similar to Figure 12 but further cut away, showing a still further stage in folding the end flaps of the carton,

.Figure 15 .is a perspective view of the carton, in an initial stage of formation, corresponding to the machine position shown in Figure 9,

Figure 16 is a perspective view of the carton, in a further stage of formation, corresponding to the machine position shown in Figure 10,

Figure 17 is a perspective view of the carton, in a further stage of formation, corresponding to the machine position shown in Figure 11,

Figure 18 is a perspective view of the completely folded carton, formed by my machine, 7

Figure 19 is a cross-sectional view, partially cut away, taken along the line 19--19 of Figure 9, and additionally showing in broken lines movement of the machine and a further stage of formation of the carton,

Figure 20, A through D, shows the four cams principally involved in the operation of my machine, in their simultaneous position, corresponding to the position of the machine shownin Figures 3, 4 and 5, the views being taken, respectively, along the lines 20A of Figure 5 and 20B, 20C and 20D of Figure 4,

Figure 21 is a front perspective view showing in detail a right-hand portion of the forming head and die,

Figure 22 is a front perspective view, partially in phantom, showing in detail a left-hand portion of the forming head and die, and

Figure 23 is a front perspective view showing in still further detail a left-hand portion of the forming die.

Referring to the drawings, Figure 1 shows a single blank 10, as disclosed in Patent 2,624,521, made from paperboard or other flexible material, upon which my machine acts to set up as a carton. Blank 10 is suitably divided by cut and score lines into a front wall 11, a bottom wall 12, a rear wall 13, a cover 14 and a cover fiap 15. Hingedly connected to the end edges of walls 11, 12 and 13 respectively, are end flaps 16, 17 and 18. Outwardly-extending roll-retaining flaps 19 are hingedly connected to the outer edges of end flaps 17 along transverse score lines 24, and dust flaps 20 are hingedly connected to a side edge of end flaps 18 along longitudinal score lines 25. A serrated metal knife edge 21 is suitably affixed to the free edge of front wall 11 for easy severing of desired lengths of the sheet material to be packaged.

Figure 2 shows the finished carton, to be set up by my machine fromthe blank of Figure 1, and containing a roll 22 of sheet material 23 to be dispensed from the carton. Roll retaining flaps 19 extend into the ends of hollow roll 22 to prevent the roll from dropping out of the carton when the cover 14 of thecarton is opened and the carton is inverted. This feature is fully disclosed and claimed in aforementioned Patent 2,624,521.

My machine, as shown in Figure 3, includes a main frame 30 anda super-structure frame 31 suitably mounted thereon, for supporting the working components of the invention. The machine is driven by any suitable power means (not shown), such as an electric or gasoline motor or the like connected to-the main drive shaft 32 by means such as chain 33 and sprocket 34 to drive shaft 32 in the clockwise direction as viewed from the right of Figure 3.

Referring also to Figures 4, 5, 6 and 7, it is seen that frame 30 supports fixed shaft members 35, 36 and 37 upon which a number of essential parts of my invention are fixed or guided. Super-structure 31 has slidably journaledtherein for vertical movement a bar member 38, within which is slidably mounted a second bar member 39. On the lower end of bar 38 is suitably aflixed a member 40, which is a part of the forming head indicated in general by numeral 41. Member 40 is integrally formed of parts 40a, 40b and 150 as shown in Figures 8, 9 and 19. Member 42, which is the other part of forming head 41, is suitably afiixed at the lower end of bar member 39. The function of member 42 is to press the carton blank 18 downwardly through suitable forming dies to be described later. The function of member 40 is to guide and support the end flaps of the blank during the carton forming operation, these members being actuated in timed relation by means hereinafter described. Bar 38 together with member 40 form one plunger, while bar 39 and member 42 together form a second plunger.

The carton forming die is composed of a front female die member 43, a pair of rear female die members 44, a pair of plow or female die members 45, a second pair of plow or female die members 46 and a third pair of plow or female die members 48. As shown, and for purposes of convenience in maintenance, front member 43 is laterally divided into two portions, but this is not an essential feature of my invention. Member 43 is supported on spaced members 36a which in turn are adjustably supported on upright members 36b carried on fixed shaft 36, as shown in Figure 9. As shown in Figure 6, the rear members 44 are supported on adjustable supporting members 37a which are supported on uprights 37b in turn supported on fixed shaft 37. Paired plow members 45 are fixed to the front member 43 of the die as shown in Figure 10. Paired plow members 46 are mounted on supports 47, as shown in Figure 15, which in turn are mounted on shafts 36 and 37 for horizontallyslidable movement as will be explained later and as shown in Figures 4 and 5. Paired plow members 48 are carried at the ends of arms 49, the arms 49 being slidably supported by supports 47 and at their remote ends fixed to supports 50, which in turn are fixedly mounted on shafts 36 and 37. The function of plow members 45, 46 and 48 is to inwardly fold end flaps 16, 18 and 17, respectively. Each of supports 47 is actuated for horizontallyslidable movement relative to its supporting shafts 36 and 37 by means of a linkage comprising toggle links 51 and 52, push rod 53, and cam arm 54 as shown in Figures 4 and 5. Toggle links 51 and 52 are pivotally connected to supports 47 and main frame 30 by means of pins 55 and 56, all respectively. Toggle links 51 and 52 and push rod 53 are pivotally connected together at 57, and push rod 53 at its lower end is pivotally connected to earn arm 54 by ball and socket joint 58. With additional reference to Figure 200, each cam arm 54, which at its rear end is pivotally mounted on a fixed shaft 59, carries a cam follower 60 which is actuated by a cam 61 on drive shaft 32 to produce up and down movement of push rod 53. This movement, due to the linkage just described, results in horizontal movement of slidable support 47 and die member 46 carried thereby. The mere weight of the linkages insures continuous contact between cam followers 60 and cams 61, though if desired springs or the like might be conventionally used to assist this contact force.

A horizontally-slidable tongue 62 is mounted within each of arms 49 (see Figures 4, 5, 10, 11, 14 and 21 to 23). The bottom rear portion of each tongue 62 is toothed to form a rack 62a, which meshes with pinion 63 fixed adjacent one end of a shaft 64 as shown in Figures 4 and 5. Shaft 64 is rotatably journaled within slidable support 47, and has fixed adjacent its opposite end a second pinion 65, which in turn meshes with a rack 66 slidably journaled in support 50 and member 130 supported on a member 130a fixed to shaft 37. Rack 66 is pivotally connected to a bell crank 67 by a link 68. intermediate its ends, bell crank 67 is pivotally jou rnaled to bracket 69 on main frame 30. With additional reference to Figure 20D, bell crank 67 carries at its end opposite that to which link 68 is attached a cam follower 70, which is actuated by a cam 71 fixed to a rotating shaft '72 journaled in main frame 30. Shaft 72 is connected to main drive shaft 32 for direct rotation therewith by means of a sprocket 73 on shaft 72, a sprocket 74 on shaft 32, and a chain 75 connecting sprockets 73 and 74. It will readily be seen that through the linkage of chain '75, sprockets 73 and 74, cam assembly 70, 71, bell crank 67, link 63, rack 66, pinions 63 and 65, and shaft 64, rotation of shaft 32 will cause back-and-forth horizontal movement of tongue 62. Cam followers 70 may be maintained in continuous contact with face cams 71 by means such as tension springs 131 connected between racks 66 and members 130.

Referring particularly to Figures 3 and 6, it is seen that main frame 30 and super-structure frame 31, respectively, carry pairs of supporting arms or extensions and 81, in which are journaled two shafts, 82 and 83. Keyed to the central portion of shaft 82 are two arms 84, which by means of links 85 are connected to bar member 33. A third arm 86 is keyed at one end to shaft 83, and at its other end is pivotally connected to one end of a link 87 which in turn at its other end is pivotally connected to bracket 88 fixed to bar member 39.

Shaft 82 carries adjacent'one end another arm 89, to which, with adjustability as at 90, is pivotally connected a push rod 91 by means'of connecting element 91a. The lower end of push rod 91 is connected to a connecting element 9112 which carries a cam follower 92. Cam follower 92 engages the raceway of a box cam 93 keyed to main drive shaft 32. With additional reference to Figures 5 and 20A, it is seen that the lower end of push rod connecting element 91b is steadied and supported by a link 94 pivotally connected at one end to the lower end of the push rod connecting element 91b and at the other end to fixed shaft 59. From the above description, it will be readily seen that rotation of main drive shaft 32 will result in up-and-down corresponding movement of bar member 38.

With reference to Figures 3, 4, 6 and 20B, it is seen that shaft 83 has keyed adjacent one end an arm 100, to which is pivotally connected a push rod 101 by means of connecting element 1010. At its lower end push rod 101 is connected to a connecting element 101]) which carries a cam follower 102. Cam follower 102 engages within the raceway of a box cam 103 keyed to main drive shaft 32. A link 104, pivotally connected to the lower end of push rod connecting element 101!) and to fixed shaft 59, steadies and supports the lower end of push rod connecting element 101b. From the above description, it will readily be seen that rotation of main drive shaft 32 will result in up-and-down movement of bar member 39.

With particular reference to Figures 10, 19 and 22 it will be seen that forming head member 42 carries internally thereof at each end a lever 110, which adjacent itsmid point is rotatably connected to forming head member 42 by means'such as a pin 111 (see Figure 19). These levers are normally constrained to lie in a substantially horizontal plane by the action of springs 112 connected at one end 112a to the inner ends of levers 110 and connected at their other ends 112b to the central portion of member 42 of forming head 41. These springs 112 are normally under tension to provide the force tending to constrain the levers 110 to lie in the horizontal plane. With reference also to Figure 19, it is seen that'the outer ends of these levers 110, due to the tension of springs 112, normally tend to lie outside 1 die.

5. the inner members 150 of forming head member 40 but that upon the coming together of the two members 40 and 42 of forming head 41 members 150 will exercise a force upon levers 110 causing those levers to 'assume a substantially vertical position and lying entirely within the inner boundary of the forming head member 40. The effect of this function will be explained in detail later herein.

'As shown in Figure 10, member 121 is supported on the spaced cross-members 36a and in turn 'adjustably carry supporting rods 120a to the inner ends of which are affixed stops 120. Stops 120 are adapted to position the carton blank in proper location over The operation of my carton forming machine may now be described. With reference to Figures 1', 3 and 8, the upper surfaces of end flaps 16 and 18 of blank 10 are coated with any suitable adhesive substance and the carton blank 10 is then placed within my machine for the forming operation, with the surface of the'blank and with the knife edge 21 against stops 120. At this time my machine is in the position shown in Figure 3 with the cams in the positions shown in Figure 20. The placement of the adhesive, and the positioning of the carton blank in the machine, may be done either by hand or by automatic mechanical means of any conventional-sort well known to those versed in the art.

After the carton blank is thus inserted, the initial rotation of shaft 32 as previously described will, through cam 103 (Figure and the connecting linkage previously mentioned (see also Figure 6), force forming head member 42 downwardly into contact with the bottom wall 12 of the carton blank 10, there being at this initial stage no corresponding downward movement of forming head member 40. Very closely after the initiation of this movement, the rotation of shaft 32 acts upon cam follower 60 (Figure 20D) to produce a slight inward horizontal movement of supports 47 carrying plow members 46.

With particular reference to Figures 8 and 9, and additionally to Figure 20, it is seen that further rotation of shaft 32 results in further downward movement of forming head member 42, with consequent impression of carton blank 10 into the forming die, the front die members 43 causing an erection of front wall 11 and the rear die members 44 causing an erection of the rear wall 13 with respect to the bottom wall 12, and the die members 48 causing a similar erection of the end flaps 17 carrying with them retaining flaps 19. As forming head member 42 commences its downward movement separate from member 40, levers 110 under the influence of springs 112 pivot toward a horizontal position until, as

, seen in Figure 9, as member 42 leaves member 40 completely the free ends of levers 110 are in contact with end flaps 17 just below the connection between that flap and roll retaining flaps 19. This is also clearly seen in Figure 19.

Figure 10 illustrates the next step of the operation, in which cam 71 (Figure 20D) has acted through the linkage previously described to force tongue 62 in against roll retaining flaps 19, bending flaps 19 inwardly, end flaps 17 being held from 'infolding movement by the pressure of levers 110. As also seen in Figures 10, cam 93 has been rotated to the point where the linkage actuated thereby has caused initial downward motion of forming head member 40, whileportion 42of the form-,

ing head proceeds downwardly-at a slower rate. Referring also to Figure 11, as forming head member 40 proceeds rapidly downwardly, tongue 62 is retracted and members 1.50 fixed to member 40 strike levers 110 outwardly of their pivot points 111, causing the levers to pivot (clockwise as shown in Figure 11) out from under side portions 1220f forming head member 40, and also out from under roll-retaining flaps 19. As this occurs,

the forming I '20 to which the adhesive had been applied being uppermost 22 will simplify understanding of the description given;

the bottom surfaces of side portions 122 contact rollretaining flaps 19, whereupon further downward movement of forming head member 40 bends these roll-retaining flaps downward substantially'into face to face contact with the inner surfaces of end flaps 17. For' this point of the operation, additional reference might be had to Figure 19.

During the final portion of the above stage of operation, the slow downward motion of forming head member 42 has brought end flaps 16 and 18 into contact with plow members 45 and 46 respectively, causing initial infolding of those flaps (see also Figures 12 and 14). At this point, cam 93 has brought forming head member 40 down into the overlapping and joined position with member 42 from which these two members initially started as seen in Figure 3, whereupon further rotation of shaft 32 causes the forming head 41 as a unit to continue downward motion through the die members 43 and 44 and plows 46 and 48.

With reference to Figures 13, 14 and 19, it is seen that this continued motion of the forming head 41 results in continued in-folding of end flaps 16 and 18. motion carries the carton being formed below the lower ends of plow members 48 and into retaining pocket-like female die members 123 fixed to supports 47 and shaped to the contour of the carton ends (seealso Figure 23). as forming head 41 has forced the blank below the plow member 48, and end flaps 16 and 18 have been infolded so that flap 16 overlies the outer surface of flaps 17 and flap 18 overlies the outer surface of flap 16, the exterior surface of bottom wall 12 is at its ends in contact with retaining member 123. At this point, cam 61 (Figure 20C) causes an additional inward movement of slidable supports 47, carrying retaining members 123 with them, and resulting in a squeezing of the closely-overlapping end flaps 16, 17 and 18 between retaining members 123 and the outer surfaces 122 of forming head part 4011 as shown in Figure 19. This gives the adhesive which has been applied to the end fiaps of the carton blank a chance to obtain a firm grip, resulting in a strong adhesive connection, the inner surface of flap 16 being adhered to the outer surface of flap 17 and the inner surface of flap 18 being adhered to the outer surface of flap 16.

Immediately thereafter, the contour of cam 61 causes withdrawal of support 47 and retaining member 123, and then cams 93 and 103 cause a joint withdrawal of the two portions of forming head 41 upwardly toward the original position shown in Figure 3. As this withdrawal takes place, the formed carton is prevented from accompanying this withdrawal by a pair of spring-mounted catches 124 (Figures 6, 21 and 22) mounted on rear die members 44 which contact the upstanding free edge of cover flap 15 to restrain the formed carton. As soon as frictional contact between the formed carton and the forming head ceases, due to the withdrawal of the form ing head, the force of gravity causes the formed carton to fall downwardly and out of the machine being guided by guide bars 150. If desired, a conveyor or other means may be located below the machine to receive the formed cartons as they fall, to convey them to a point of filling or other use, for example, to be filled with a roll of sheet material, as shown in Figure 2.

After the forming head 41 has returned to the uppermost position shown in Figure 3, the machine is ready to receive another carton blank for formation.

Additional reference to Figures l5, l6, 17, 18, 2l and Figure 15 shows the carton in a position approximately corresponding to the machine position illustrated in Figure 9, wherein end flaps 17 of the carton blank have been erected relative to bottom wall 12, and levers have extended outwardly to press against the inner sur faces of end flaps 17 below their hinge connection with roll-retaining flaps 19. Figure 16 corresponds approximately to Figure 10, the tongues 62 having protruded This inwardly to flex roll-retaining flaps 19 inwardly with respect to flaps 17. Figure 17 corresponds to Figure 11, wherein the forming head has moved downwardly a suflicient distance to initiate the inward-folding action of plow members 45 and 46 on end flaps 16 and 18, respectively, and outer surfaces 122 of forming head part 40a have begun to bear downwardly on roll-retaining flaps 19. Figure 18 is a perspective view of the finished carton, as it would be formed at the stage shown in the broken-line, second-stage, view of Figure 19.

It will be obvious that for many of the mechanical details of my machine illustrated and described equivalent means might be substituted without basically changing the mode of operation and without departing from the guiding principles and the spirit of my invention. It is therefore to be understood that the foregoing description is not to be considered a limitation upon my invention, but rather the only limitations intended are those set forth in the following claims.

I claim:

1. Apparatus for forming a cut and scored flat carton blank into hollow carton form, the blank having a bottom wall, front and rear walls hinged to opposite side edges of the bottom wall, first, second and third end flaps hinged to opposite end edges of the front, bottom and rear Walls, respectively, the second end flaps being divided by intermediate transverse score lines to define outwardly-extending retaining flaps hinged to the second end flaps, and an adhesive coated onto at least two surfaces of each set of end fiaps, said apparatus comprising a first plunger shiftable perpendicularly with relation to the bottom wall of the blank to contact the upper surface of the bottom wall to move the blank in a direction perpendicular to said wall, first fixed female die members to engage the front and rear walls and second end flaps to erect said walls and flaps perpendicularly to the bottom wall as the blank is initially moved by said first plunger, a pair of levers movably mounted upon said first plunger and biased to contact the erected second end flaps below said transverse score lines, a pair of shiftable members mounted on said first female die members to press said retaining fiaps inwardly to overlie the bottom wall, a pair of second and of third female die members to engage the first and third end fiaps to erect said flaps perpendicularly to the bottom wall and erected front and rear walls, a second plunger shif able perpendicularly with relation to the bottom wall of the blank to press said retaining flaps into substantially face-tc-face contact with the inner surface of the second end flaps below said transverse score lines and to thereafter resist pressure tending to force the end flaps inwardly of the ends of the bottom, front and rear walls, fourth female die members shiftable perpendicularly to the erected end flaps to press said erected flaps against the second plunger to create an effective adhesive bond between such fiaps, one pair of said pairs of second and third female die members being fixed and the other mounted on said fourth female die members, and means so interconnecting the previously-mentioned elements of the apparatus that successively the first plunger contacts the bottom wall of a blank placed flatwise upon the first female die members to press the blank therethrough to erect the front and rear walls and second end flaps, the movable levers contact the erected second end flaps below said transverse score lines, the shiftable members shift to press the retaining fiaps inwardly to overlie the bottom wall, the second plunger shifts to contact the upper surface of the inwardly-pressed retaining flaps to force them into face-to-face contact with the second end flap below said transverse score lines, the movable levers being forced away from said second end flaps by movement of the second plunger, the first and second plungers together shift the blank to engage the first and third end flaps with the second and third female die members to erect said fiaps perpendicularly to the bottom wall and the erected front and rear walls, and the fourth female die members shift to press the erected end flaps against the second plunger to effect a secure adhesive bond between the end flaps.

2. Apparatus for forming a cut and scored fiat carton blank into hollow carton form, the blank having a bottom wall, front and rear walls hinged to opposite side edges of the bottom wall, first, second and third end flaps hinged to opposite end edges of the front, bottom and rear walls, respectively, the second end flaps being divided by intermediate transverse score lines to define outwardly-extending retaining flaps hinged to the second end flaps, and an adhesive coated onto at least two surfaces of each set of end flaps, said apparatus comprising vertical1ymovable first means to contact the upper surface of the bottom wall to move the blank in a direction perpendicular to said wall, fixed second means to support such blank placed thereon and engage the front and rear walls and second end fiaps for erection thereof perpendicular to said bottom Wall upon initial movement of the blank therethrough by said first means, third means mounted on said first means to engage the inner surface of the erected second end flaps below said transverse score lines to prevent folding of said flaps below said score lines over the bottom wall, shiftable fourth means mounted on said second means to press said retaining flaps inwardly to overlie the bottom wall, fifth means to engage the first end flaps and sixth means to engage the third end flaps to erect said flaps perpendicularly to the botom wall and erected front and rear walls, seventh means to engage the inwardly-pressed retaining flaps to press said flaps downwardly into substantially face-to-face contact with the inner surface of the second end flaps below said transverse score lines and to resist pressure tending to force the end flaps inwardly of the ends of the bottom, front and rear walls, movable eighth means to press the erected end flaps against the seventh means to create an effective adhesive bond between such flaps, one of said fifth and sixth means being fixed and the other being mounted on said eighth means, and means so interconnecting the previously-mentioned means that upon initial movement of the blank through the second means by the first means the front and rear walls and second end flaps are erected perpendicular to the bottom wall and the third means contacts the second end walls below said transverse score lines, upon further movement of the blank by the first means the fourth means engages said retaining flaps to press them inwardly over the bottom wall, upon still further movement the seventh means engages the thus-positioned retaining flaps to press them into substantially face-to face contact with the inner surface of the second end flaps below said transverse score lines, and thereafter the first and seventh means moving together force the blank further through said second means to engage the first and third end flaps with the fifth and sixth means to erect those fiaps perpendicular to the front, rear and bottom walls, and thereupon the eighth means move inwardly to press said flaps against the seventh means to create the effective adhesive bond between those flaps.

References (Iited in the file of this patent UNITED STATES PATENTS 1,724,529 Stokes Aug. 13, 1929 1,835,401 Joslin Dec. 8, 1931 2,132,859 Mednick et al Oct. 11, 1938 

